SR5runner LOTS OF PICTURES

greyghost1 · Feb 1, 2012

I have been working on this for awhile and finally finished the SAS and got it out on the trails a few times last year

TG springs, duals, 4.7, triple sticks, Longs, locked F&R, onboard air and a bunch of other goodies

Since I have kids the extra cab was too small and I needed to do something about it

CHOP 9"

TEST FIT BEFORE I MOVED THE AXLE UP 10"- STARTING TO GET THE IDEA

HERE IS THE DONOR BODY FOR THE REAR SEAT, TOP AND FLANGE

HERE IS A PEEK AT THE TOP FLANGE INSTALLED AND AXLE MOVED UP 10"

REAR SEAT PAN INSTALLED

CUT OUT THE ROCKERS

3X3 BOX CAPPED READY TO GO

NEW ROCKERS INSTALLED

SLIDERS INSTALLED THROUGH THE ROCKER

SLIDERS FINISHED UP AND FENDER FLAIRS

A LITTLE SHEETMETAL WORK

EXO HOOP

START OF CAGE AND SLIDERS AND TAILGATE INSTALL

TAILGATE INSTALLED AND WINDOW WORKING

INTERIOR INSTALLED AND REAR SEAT FOR THE KIDDOS

WINDSHIELD BARS AND ROOF BARS

HALF OF MY CAGE WELDED UP AND FRONT FENDER NOTCHED

BOTTOM OF FENDER

greyghost1 · Feb 1, 2012

FRONT BUMPER IN THE WORKS

SOME GOODIES

Anthony1 · Feb 1, 2012

Looks good:awesomework::beer:

NotSoPC · Feb 1, 2012

I like it. Keep up the good work its going to be a real one of a kind.

zukkev · Feb 2, 2012

I dig it

...Have seen this before, but on a 2nd Gen excab pickup, not on a 3rd gen...

greyghost1 · Feb 2, 2012

zukkev said:
I dig it ...Have seen this before, but on a 2nd Gen excab pickup, not on a 3rd gen...

That is all I found also, I hope its the only one out there when I'm done!

greyghost1 · Mar 4, 2012

just picked up my new tires, 37x14x17 bias iroks

17x9 soft 8s, I had the wheels made with 3.5" BS instead of 4.5" for a little extra width

I picked up the rest of my tubing for the cage and rear bumper last weekend and bought my beadlocks from D&J Customs, I chose to clean them up myself so here are the pics

Cleaning up the edges alittle

Prep on the wheel

welded in the hole for the valve stem so I can drill in a new one further in away from the beadlock

All welded up

greyghost1 · Mar 4, 2012

Made some progress with the gas tank, I am going to use a Ford F-series aux tank out of a 92 pickup it is the 18 gallon one the dimensions are 34.5x26.5x8

First things first, pour out as much gas as you can out of both tanks and open up everything that can be opened then toss in some matches until it stops igniting any gas
Please use some commen sence when doing this step.

next I cut the flanges out of the toyota tank

I layed them out on the Ford tank to get an idea of where I wanted them

This part I have to do because of my limited space under the truck but I have seen other write ups that the unmodified tank will fit. I cut 4" off of the end of the tank and welded 18 gauge sheet metal to cap it off. I am going to install the filler spout and vent to the front in my new capped end on the upper passenger side so I can route the filler from the stock location.

I mounted the toyota pump and sending unit into the middle of the ford tank, I also welded the toyota baffle to the floor of the ford tank.
There is some light modification needed for the pump and sending unit, the pump needs to be shortened up to fit down into the tank

and the sending unit just needs to be cut and bent so it has full swing inside the tank

Here is the baffle from the toyota tank, I drilled out the spotwelds and then attached it to another piece of clean sheet metal and tacked it under the pump in the ford tank

greyghost1 · Mar 4, 2012

Make sure you line up your flanges with the pump bolted in them, they are clocked, we welded in the flanges then found out the pump was facing the wrong way and my sending unit was going right through my pump, easy fix if you do the same I just redrilled a couple holes and they fit once again.

I had my buddy weld the tank for me since he has been welding alot longer than I have been, I am glad he did weld it, we only had a handful of leaks when we tested it instead of hundreds of leaks if I would have done it

when everything was welded and cooled we pressure tested the tank and sprayed the welds with soapy water, after we got done fixing the leaks we trimmed the extra sheetmetal off, I left the stock filler in the tank for now because someday I might move my filler door over to the drivers side so I can fill my tow rig and wheeler without moving to a new pump, I can just pull foward

Fixing the leaks

One last test

All trimmed up

I also have the drain bolt out of the toy tank that I think I am going to put it in just incase I need to pull the tank someday

greyghost1 · Mar 4, 2012

Working on the beadlocks tonight, I got a helper too, she is super excited

We are working on making a anti cone ring, I am using 3/4"x 1/8" and just tacking it and bending it as I go

here is on of the rings set on to show how its going to look

My wife blasted all of the outer rings for paint

here are the rings painted up and drying

I also got some more tube work tacked up

dirk · Mar 4, 2012

Looks good little brother...looking forward to the finished product!

:beer:

greyghost1 · May 25, 2012

I have done alot to the rig and have not updated NWW, here is the update to current.

Ford tank, we installed a tube crossmember through the end of the frame and welded it inside and out. Next we mocked up the tank to figure out the front crossmember and shock mount.

Here is the shock mount/tank mount crossmember

Next I made some tabs like the TG offroad light ones

Also added the filler port and vent, I can use my factory filler neck and just add some hose to it to connect the tank back up

Front view, I have to flex it out to see if my tabs for the tank straps are going to clear before I burn them in....Tight fit!

Side profile

Here are all the connections, fit perfect just between the floor braces, I used 1/2" thick rubber that I will glue onto the top of the tank so it doesnt rub anything.

greyghost1 · May 25, 2012

Mounted the iroks, hooked up the fuel lines and fired it up, patched in the rest of my rear fenders and took it out to my buddies house for alittle body work.

Had a couple of friends help me mount the beadlocks, all those bolts take forever

Here are the patch panels to finish the rear tube fenders

Finally got it outside so I can take a few pictures of the whole rig

I am glad I know someone who can do some body work
If I tried to do this myself it would get all fawked up

All I can say is bodywork sucks, my finger tips are raw from sanding

My buddy sanding the final coat of thin filler

And here is the final product in primer, now I just need to finish the exo and paint it

I took 10" out of my rear shaft and sleeved it for now just so I can go wheeling this weekend, I am going to retube the driveline and get it balanced soon but until then we used a jig made with some tcase output shafts so we could get it as true as possible

I got the rig outside and took some posers

I only have the rear hoop for my bumper, mounts and braces will be built before friday. The cage is complete minus paint

I also have the rear window switch installed in the dash and it is functional

greyghost1 · May 25, 2012

I added a plate under my fenders to tie the front of the cage into the body by the kick panels, I had to pull the fuse panel and computer away to make sure the heat didnt melt any wires

Added braces to the rear bumper, I still am going to add a reciever and lower tube to the bumper to finish it off

Tape off the tubing and painted it

a couple shots next to 87/4play

greyghost1 · May 25, 2012

Finally got to go test it out on Sunday, we went to Walker Valley for the day, everything worked just about as good as it could, I have a couple of spots to clearance for the tires but it still worked just fine.

87/4play

cant forget the burrito basket

The only thing I F'd up was my rear driveline, I got alittle rock rash on it and it wrinkled some.....time to redo it the right way with some thicker tube.

I was pretty excited that everything worked so good and I had all the room for my gear and kiddos.